Process modeling and optimization of the staggered backward flow forming process of maraging steel via finite element simulations

Shinde, Hemant; Mahajan, Pushkar; Singh, Abhishek Kumar; Singh, Ramesh; Narasimhan, K.

doi:10.1007/s00170-016-8559-7

Cited by 33 publications

(12 citation statements)

References 11 publications

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“…They concluded that the final shape of spinning process depends on roller geometry, feed rate and the amount of deformation. Shinde [3] found that the roll forming angle, feed rate and thinning rate are important process parameters affecting the diameter expanding and ovality of the steel tube in backward spinning. Xu and Zhang [4] obtained the distribution of stress and strain rate during spinning of tube parts by finite element method and concluded that the forming quality is determined by the size of tube and roller, feed, thickness reduction, the number of rollers and nose radius.…”

Section: Introductionmentioning

confidence: 99%

Stability research on spinning of ultra-thin-wall aluminum alloy tube

et al. 2020

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In this paper, the instability in spinning process of ultra-thin-wall tube is analyzed, and the influence law of different parameters of roller and main process parameters in spinning forming process. Firstly, the forward spinning finite element model of ultra-thin wall tube is established and its reliability is verified. It is concluded that the instability of ultra-thinwall aluminum alloy tube during spinning is caused by its poor rigidity and material flow disorder. The effects of different parameters of roller (roller diameters, roller forming angles and roller corner radii) and the main process parameters (feed rates, friction coefficients and thinning rates) on the equivalent plastic strain and diameter expansion amount in spinning forming process were investigated. The results show that the influence of each parameter on the stability of ultra-thin-wall is quite different. The influence of roller corner radius is stronger than roller diameter and much stronger than roller forming angle. The influence that feed rate does the expansion amount to exist a minimum value. The friction coefficient and thinning rate have positive correlation with expansion amount. The optimum combination of process parameters was further determined, and the accuracy of the results was verified by experiments, which provided reference and guidance for actual production.

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Section: Introductionmentioning

confidence: 99%

Stability research on spinning of ultra-thin-wall aluminum alloy tube

et al. 2020

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“…Also, roller and mandrel are taken as analytical rigid bodies (do not require meshing) which helps to reduce computational time and memory storage. The mesh sensitivity analysis is carried out based on the procedure proposed by [10] to decide optimum mesh size. The optimum mesh size is decided by taking several mesh size from 0.5 to 5 mm (in interval of 0.5 mm).…”

Section: Discussionmentioning

confidence: 99%

“…Xia et al [9] had done the analysis of flow forming for non axisymmetrical geometry. Shinde et al [10] had studied the effect of different parameters during three roller forward flow forming using facecentred central composite design (CCD) for Maraging steel.…”

Section: Fig 2 Backward Flow Forming Configurationmentioning

confidence: 99%

Optimization of Process Parameters during Flow Forming Process and its Verification

Bhatt

Raval²

2017

mech

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“…Further, they have opined that predictions of a 1/24th domain model are more reliable as it has been built with finer mesh system. Shinde et al [57] have used ABAQUS/explicit to develop a 3D thermo-mechanical finite element model for reverse flow forming of a cylindrical workpiece made up of maraging steel. They have studied the effect of feed rate and thickness reduction ratio on stress/strain distribution and roller forces.…”

Section: Modelling Of the Process Using Finite Element Methods (Fem) mentioning

confidence: 99%

Flow forming of thin-walled precision shells

et al. 2018

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Flow forming is an innovative form of cold and chipless metal forming process, used for the production of high precision, thin-walled, net-shaped cylindrical components. During this process, the length of a thick walled tube, commonly known as a preform, is increased with a simultaneous decrease in the thickness of the preform without any change in the internal diameter. Forming of the preform is carried out with the help of one or more rollers over a rotating mandrel. By a predetermined amount of thickness reduction in one or more number of forming passes, the work material is plastically deformed in the radial direction by compression and made to flow in an axial direction. The desired geometry of the workpiece is achieved when the outer diameter and the wall of the preform are decreased, and the available material volume is forced to flow longitudinally over the mandrel. Over the last three and a half decades the flow forming technology has undergone several remarkable advancements. The versatility of the process makes it possible to produce a wide variety of axisymmetric, nearer to the net-shape tubular parts with a complex profile using minimum tooling changes. In this review article, process details of flow forming have been elaborated. The current state-of-the-art process has been described, and future developments regarding research and industrial applications are also reviewed.

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Process modeling and optimization of the staggered backward flow forming process of maraging steel via finite element simulations

Cited by 33 publications

References 11 publications

Stability research on spinning of ultra-thin-wall aluminum alloy tube

Stability research on spinning of ultra-thin-wall aluminum alloy tube

Optimization of Process Parameters during Flow Forming Process and its Verification

Flow forming of thin-walled precision shells

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